The revision of IEC 60034-2-1 and the new

IEC 60034-2-3 for efficiency determination of

converter-fed machines
The revision of IEC 60034-2-1 and the new IEC 60034-2-3

Overview

• Where do we come from? - Changes at the Introduction of IEC60034-2-1

• The Round-Robin Test – Targets, Results and Conclusions
• Improvements for the next Edition of IEC 60034-2-1
• Efficiency classes for converter-fed machines – The driving force behind IEC
60034-2-3
• Outlook

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The revision of IEC 60034-2-1 and the new IEC 60034-2-3

Where do we come from? - Changes at the introduction of IEC 60034-2-1

• Introduction of efficiency classification for induction motors according to

IEC60034-30 caused the necessity to update IEC60034-2
• Main objective was to increase the reliability of the efficiency values determined
on the basis of this standard
• The well-know figure of 0,5 % of PN as assigned value for the additional load
loss was replaced by a curve, giving the upper value of the additional load loss of
a large population of motors in dependence of machine rating
• Introduction of new test procedures for measuring the additional load loss
instead of using the assigned value
• Determination of additional load losses from direct testing (residual losses)
similar to IEEE 112 and introduction of Eh-star method

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The revision of IEC 60034-2-1 and the new IEC 60034-2-3

Where do we come from? - Changes at the introduction of IEC 60034-2-1

New philosophy:

Standardised factor of 0,5 %

was replaced by a curve
giving the upper value of the
additional load losses of a
large population of motors
versus the rated output
power.

 Measurement becomes
more attractive than
using the assigned value

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The revision of IEC 60034-2-1 and the new IEC 60034-2-3

Where do we come from? - Changes at the Introduction of IEC 60034-2-1

Test-Setup for the Eh-star test

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The revision of IEC 60034-2-1 and the new IEC 60034-2-3

The Round-Robin Test – Targets

Part 1: A series of tests in the same laboratory on a single motor

• Quantification of differences between different test methods
• Determination of the influence of testing tolerances, i.e. impact of operator
errors and test equipment

Part 2: A series of tests in the same laboratory on motors of the same

design, from different manufacturing cycles, using the same test
method
• Determination of uncertainty caused by variations in material properties and
manufacturing processes

Part 3: A series of tests by different laboratories on the same motor

• Identification of uncertainties due to different interpretations of the test
procedures, differences in instrumentation and laboratory equipment and
personnel variations
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The revision of IEC 60034-2-1 and the new IEC 60034-2-3

The Round-Robin Test – Results

Part 1: A series of tests in the same laboratory on a single motor

• Good correlation between Eh-star and residual loss for additional load losses
up to about 1000 W. Corresponds to machine ratings of approx. up to 150 kW.

Part 2: A series of tests in the same laboratory on motors of the same

design, from different manufacturing cycles, using the same test
method
• Significant variation of losses determined for the same motor design at different
points of time. A variation of the total losses of approx. 5% is solely caused by
material and manufacturing tolerances.

Part 3: A series of tests by different laboratories on the same motor

• Part of the laboratories determined higher losses by the Eh-star method, while
the other part did this for residual loss. In some cases two consecutive
measurements of the same laboratory on the same machine using the same
method resulted in a difference of additional losses by more than 100%.
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The revision of IEC 60034-2-1 and the new IEC 60034-2-3

The Round-Robin Test – Conclusions

• With respect to practical reasons the method of residual loss will be introduced
as preferred method to determine the additional load loss for compliance
checks with national energy efficiency regulations for all 3-phase machines with
ratings up to 1 MW
• All other methods, including Eh-star, will be kept in the standard for field- or
routine testing
• The total loss tolerance of +10% stated in IEC 60034-1 for machine ratings
above 150 kW seems to be reasonable based on the part two results
• Especially part 3 of the Round Robin Test illustrates the need to clarify the test
procedures themself and to give clearer guidelines how to perform the testing
and how to evaluate the test results.
The results give clear indication that not the procedure itself causes primarily
the uncertainty of the test results, but the processing of the measurements and
evaluations

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The revision of IEC 60034-2-1 and the new IEC 60034-2-3

Improvements for the next Edition of IEC 60034-2-1

Distinguishing between preferred methods for minimum energy performance
standard measurements and methods for field and routine testing

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The revision of IEC 60034-2-1 and the new IEC 60034-2-3

Improvements for the next Edition of IEC 60034-2-1

Distinguishing between preferred methods for minimum energy performance
standard measurements and methods for field and routine testing

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The revision of IEC 60034-2-1 and the new IEC 60034-2-3

Improvements for the next Edition of IEC 60034-2-1

• Well-defined specification of test procedures with respect to the sequence of

tests, evaluation of test results and improved readability of the standard, by
introduction of flow charts and standard test reports

Furthermore:
• Consideration of averaging of measured
data to lower uncertainty
• Consideration of test procedures for permanent
magnet excited synchronous machines

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Efficiency classes for converter-fed machines:

The driving force behind IEC 60034-2-3

• IEC 60034-2-1 focuses solely on sinusoidal supply

• Rising demand for converter-fed motors, operating at variable-speed
• These motors are not yet covered by the efficiency classification of IEC 60034-30
The definition of test procedures for the verification of minimum energy
performance standards for these motors has to deal with to principle obstacles:
• Working group 28, as a sub-committee of TC2, has to concentrate on the motor
performance
• In general the motor manufacturer does not correspond with the converter
supplier. Therefore motor efficiency testing in conjunction with the converter
intended for the final application is in most of the cases not possible

 The new Test Converter Approach of IEC 60034-2-3

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The new Test Converter Approach of IEC 60034-2-3

• Only for asynchronous machines fed by 2-level voltage sources converters.

These motor/converter-systems have a market share of approx. 90%
• The reference-converter has to be understood as a voltage source independent
of load, set at the rated voltage and fundamental frequency of the motor under
test
• To ensure reproducibility of test conditions, IEC 60034-2-3 gives clear definitions
for generating this reference voltage source for testing. Rising demand for
converter-fed motors, operating at variable-speed
• The reference conditions are not necessarily representative for the final operating
conditions of the tested motor, but they allow for comparisons between different
motor designs.
• By this, the test converter approach evens the path for the introduction of an
efficiency classification scheme for converter-fed asynchronous motors.

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The revision of IEC 60034-2-1 and the new IEC 60034-2-3

The new Test Converter Approach of IEC 60034-2-3

The reference conditions for the test converter are chosen in a way that any
conventional two level voltage source converter can be adjusted to them, so there
is no need for special equipment!

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Outlook

• The outlined improvements of IEC 60034-2-1 and the test converter approach
proposed for IEC 60034-2-3 are so far still proposals of working group 28 and
not standardized yet
• Depending on the results of the international voting process, changes are
eventually necessary
• For IEC 60034-2-1 the first CD will start circulation within 2011. Based on
experience the final version for the second edition will have passed the
international voting process in 2013 and will be available in 2013 or 2014
• IEC 60034-2-3 is already in CDV stage. Assumed the outlined idea of the test
converter set-up finds acceptance, it is likely to have the official standard
published by the end of 2012 or the beginning of 2013

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